Unified Punch Inflation and Sealing Tool

ABSTRACT

A tool for inflating a chamber ( 50 ) in an article composed at least partially of polymer layers, such as thermoplastic layers. The tool can allow for forming an aperture in a polymer layer ( 350 ), inflating a chamber ( 50 ) or volume ( 130 ) in fluid communication with the aperture, and then welding or sealing the chamber ( 50 ) so that the inflation fluid is substantially retained in the chamber ( 50 ) and/or does not escape via the aperture. In various aspects, the formation of the aperture, inflation of the chamber ( 50 ), and sealing of the chamber ( 50 ) or aperture can be performed by a single tool and/or based on a single registration of the thermoplastic article with a tool. In some aspects, formation of the aperture is enabled in part by using a punch ( 100, 201, 205 ) with a cupped surface ( 341 ) that allows the top layer of a thermoplastic article to be breached without forming a hole in at least one lower layer ( 350 ).

FIELD OF THE INVENTION

A unified tool is provided for injecting a fluid into a volume within anarticle composed at least in part of polymer layers.

BACKGROUND OF THE INVENTION

Articles of footwear generally include two primary elements, an upperand a sole structure. The upper is formed from a variety of materialelements (e.g., textiles, foam, leather, and synthetic leather) that arestitched or adhesively bonded together to form a void on the interior ofthe footwear for comfortably and securely receiving a foot. An ankleopening through the material elements provides access to the void,thereby facilitating entry and removal of the foot from the void. Inaddition, a lace is utilized to modify the dimensions of the void andsecure the foot within the void.

The sole structure is located adjacent to a lower portion of the upperand is generally positioned between the foot and the ground. In manyarticles of footwear, including athletic footwear, the sole structureconventionally incorporates an insole, a midsole, and an outsole. Theinsole is a thin compressible member located within the void andadjacent to a lower surface of the void to enhance footwear comfort. Themidsole, which may be secured to a lower surface of the upper andextends downward from the upper, forms a middle layer of the solestructure. In addition to attenuating ground reaction forces (i.e.,providing cushioning for the foot), the midsole may limit foot motionsor impart stability, for example. The outsole, which may be secured to alower surface of the midsole, forms the ground-contacting portion of thefootwear and is usually fashioned from a durable and wear-resistantmaterial that includes texturing to improve traction.

The conventional midsole is primarily formed from a foamed polymermaterial, such as polyurethane or ethylvinylacetate, that extendsthroughout a length and width of the footwear. In some articles offootwear, the midsole may include a variety of additional footwearelements that enhance the comfort or performance of the footwear,including plates, moderators, fluid-filled chambers, lasting elements,or motion control members. In some configurations, any of theseadditional footwear elements may be located between the midsole andeither of the upper and outsole, embedded within the midsole, orencapsulated by the foamed polymer material of the midsole, for example.Although many conventional midsoles are primarily formed from a foamedpolymer material, fluid-filled chambers or other non-foam structures mayform a majority of some midsole configurations.

Various techniques may be utilized to form fluid-filled chambers forarticles of footwear or other products, including a two-film technique,a thermoforming technique, and a blowmolding technique, for example. Inthe two-film technique, two separate polymer sheets are bonded togetherat specific locations. The thermoforming technique is similar to thetwo-film technique in that two polymer sheets are bonded together, butalso includes utilizing a heated mold to form or otherwise shape thepolymer sheets. In the blow-molding technique, a parison formed from amolten or otherwise softened polymer material is placed within a moldhaving a cavity with the desired configuration of the chamber.Pressurized air induces the polymer material to conform with surfaces ofthe chamber. The polymer material then cools and retains the shape ofthe cavity, thereby forming the chamber.

Following each of the techniques discussed above, the chambers arepressurized. That is, a pressurized fluid is injected into the chambersand then sealed within the chambers. One method of pressurizationinvolves forming inflation conduits in residual portions of the polymersheets or the parison. In order to pressurize the chambers, the fluid isinjected through the inflation conduits, which are then sealed. Theresidual portions of the polymer sheets or the parison, including theinflation conduits, are then trimmed or otherwise removed tosubstantially complete manufacture of the chambers.

U.S. Pat. No. 8,241,450 describes a method for inflating a fluid filledchamber. After defining a first surface, a second surface, and asidewall surface of a chamber, an aperture can be defined through thefirst surface in a location where the first surface is spaced from thesecond surface. A pressurization apparatus can then be located adjacentto the first surface and around the aperture. The pressurizationapparatus can be utilized to inject a fluid into the chamber through theaperture, compress the first surface against the second surface, andform a bond around the aperture and between the first surface and thesecond surface.

SUMMARY OF THE INVENTION

In various aspects, a tool for introducing fluid into a sealed volume isprovided. The tool includes an electrode having an outer circumferenceand an inner circumference, the inner circumference defining a volumewithin the electrode, the electrode being mechanically coupled to a baseat a first end of the electrode, the electrode being open at a secondend; an actuator mechanically coupled to the base; a punch having apunch head, the punch being coupled to the actuator, the punch headresiding within the volume in the electrode in a first punch positionand being outside of the volume of the electrode in a second punchposition, the punch head comprising a punch edge defining a perimeter, asurface of the punch within the perimeter of the punch edge beingconcave and defining a punch volume, an average depth of the punchvolume being less than an average diameter of the punch edge; and afirst fluid delivery conduit, the first fluid delivery conduit being influid communication with the volume in the electrode and in fluidcommunication with the opening at the second end of the electrode.Depending on the aspect, the punch volume can be a conical volume or aconical frustum volume; or the punch volume can be a spheroid volume oran ovoid volume; or the punch volume can be an n-sided pyramidal volumewhere n is greater than or equal to three, or a frustum volume based onan n-sided pyramidal volume where n is greater than or equal to three.Optionally, for an n-sided pyramidal volume or a frustum based on ann-sided pyramidal volume, n can be twenty or less, or twelve or less.Depending on the aspect, an included angle at opposing points of thecircumference of the punch can be about 110° to 160°. For example, theincluded angle at opposing points of the circumference can be about 120°to about 160°, or 120° to about 150°, or about 135° to about 160°, orabout 135° to about 150°.

Additionally or alternately, a tool according to any of the aboveaspects can have the average depth of the punch volume be about 0.2 toabout 0.75 times an average diameter of the perimeter of the punch edge.For example, the average depth can be about 0.2 to about 0.5 times anaverage diameter of the perimeter of the edge, or about 0.25 to about0.75 times, or about 0.25 to about 0.5 times, or about 0.4 to about 0.75times.

Additionally or alternately, a tool according to any of the aboveaspects can have the punch be mechanically coupled to the actuator by anadjustable mechanical coupling, the height of the punch head in thefirst position being adjustable based on the adjustable mechanicalcoupling. Optionally, at least a portion of the punch can be threaded,the punch being coupled to the actuator by a threaded screw coupling.

Additionally or alternately, a tool according to any of the aboveaspects can have an actuator that includes (or comprises or is) apneumatic cylinder. Optionally, the axis of the punch can substantiallycorrespond to an axis of motion of the pneumatic cylinder. Optionally, apiston volume of the pneumatic cylinder can be in fluid communicationwith a second fluid delivery conduit. Optionally, the pneumatic cylindercan be a single acting cylinder. In such an optional aspect, a restoringforce for the single acting pneumatic cylinder is provided by a spring.

Additionally or alternately, a tool according to any of the aboveaspects can have an inner circumference of the electrode that issubstantially circular, or that varies along the height of theelectrode, or a combination thereof.

Additionally or alternately, a tool according to any of the aboveaspects can have the axis of the punch be substantially concentric withan axis of the electrode.

Additionally or alternately, a tool according to any of the aboveaspects can have the first punch position and the second punch positionbe separated by a distance along an axis of motion of the actuator.

Additionally or alternately, a tool according to any of the aboveaspects can have the actuator be substantially contained within thebase.

Additionally or alternately, a tool according to any of the aboveaspects can have a clearance between the punch and the innercircumference that is from about 0.0025 inches (0.064 mm) to about 0.01inches (0.25 mm); or a clearance between the punch head and the innercircumference is from about 0.0025 inches (0.064 mm) to about 0.01inches (0.25 mm); or a combination thereof.

Additionally or alternately, methods are provided for using a toolaccording to any of the above aspects for inflating a chamber withfluid, such as a chamber in an article of footwear.

BRIEF DESCRIPTION OF THE DRAWING

FIGS. 1a and 1b show examples of a punch according to an aspect of thedisclosure.

FIG. 2 shows an example of a tool according to an aspect of thedisclosure.

FIGS. 3a-3b shows examples of variations in the position of a tool forforming an aperture in a surface according to an aspect of thedisclosure.

FIG. 4 is a lateral side elevational view of an article of footwear.

FIG. 5 is a medial side elevational view of the article of footwear.

FIG. 6 is a perspective view of a sole structure of an article offootwear.

FIG. 7 is an exploded perspective view of the sole structure.

FIG. 8 is a perspective view of a fluid-filled chamber of the solestructure.

FIG. 9 is a top plan view of the chamber.

FIGS. 10a-10d are cross-sectional views of the chamber, as defined bysection lines 10 a-10 d in FIG. 9.

DETAILED DESCRIPTION OF THE INVENTION

Overview

In various aspects, systems and methods are provided for inflating achamber in an article composed at least partially of polymer layers,such as thermoplastic layers. The systems and methods can allow forforming an aperture in a polymer layer, inflating a chamber or volume influid communication with the aperture, and then welding or sealing thechamber so that the inflation fluid is substantially retained in thechamber and/or does not escape via the aperture. In various aspects, theformation of the aperture, inflation of the chamber, and sealing of thechamber or aperture can be performed by a single tool and/or based on asingle registration of the thermoplastic article with a tool. By formingan aperture, inflating a volume, and sealing the volume with a singletool and/or single registration of the article with a tool, one or morepotential manufacturing benefits can be obtained, such as a reduced timeof manufacture, a simplified manufacturing process flow, increased timebetween maintenance cycles, and/or a reduction in manufacturing defectsin the thermoplastic articles. In some aspects, formation of theaperture is enabled in part by using a punch with a cupped surface thatallows the top layer of a thermoplastic article to be breached withoutforming a hole in at least one lower layer. Additionally, the cuppedaperture surface can allow the remnant of material originally associatedwith the aperture location to remain with the thermoplastic article.This avoids an accumulation of remnant pieces in or on the tooling.

Polymer or plastic articles with fluid-filled chambers (includingthermoplastic articles) can be used to form a variety of products.Footwear products that may include fluid-filled chambers include, butare not limited to, athletic footwear styles such as running shoes,basketball shoes, cross-training shoes, football shoes, golf shoes,hiking shoes and boots, ski and snowboarding boots, soccer shoes, tennisshoes, and walking shoes, for example. Fluid-filled chambers may also beutilized with footwear styles that are generally considered to benon-athletic, including dress shoes, loafers, and sandals. In additionto footwear, fluid-filled chambers may be incorporated into other typesof apparel and athletic equipment, including helmets, gloves, andprotective padding for sports such as football and hockey. Similarchambers may also be incorporated into cushions and other compressiblestructures utilized in household goods and industrial products.Accordingly, chambers formed using systems and methods that incorporatethe concepts disclosed herein may be used to manufacture a variety ofproducts.

Forming a fluid-filled chamber in an article composed of polymer layerscan generally involve at least three processes. First, an aperture forallowing fluid to be passed into the chamber can be defined or created,such as by punching through a wall of the chamber. Second, the fluid canbe injected into the chamber. Finally, the chamber can be sealed (suchas by closing the aperture) so that the fluid is retained within thechamber of the thermoplastic article.

One option for performing the above processes is to use a separate toolfor each process. Regardless of whether a tool is moved to the articleor whether the article is moved to a tool, a registration or alignmentprocess is typically required after each movement of a tool or thearticle. During aperture formation, the registration process can allowthe aperture to be formed in a location that provides fluidcommunication with the desired chamber. After aperture formation, theregistration process(es) allow the existing aperture to be aligned withthe tool for filling the chamber and/or the tool for sealing thechamber. During a manufacturing process, each registration processrequires additional time and possibly equipment. As a result, reducingor minimizing the number of alignment or registration processes canreduce manufacturing time and costs.

One option for reducing the number of registration processes is to use asingle tool to perform more than one task. For example, a single toolcould be used for forming the aperture and filling the chamber. However,conventional methods for using a single tool for both aperture formationand chamber filling have presented a variety of problems. Some problemshave been related to the excess material formed when an aperture isformed in a polymer layer. Typically, the article initially has acontinuous, closed exterior surface. At least this exterior surface ispunched, punctured or otherwise breached to form an aperture forinjection of fluid. If this aperture is formed by a physical method(such as by use of a mechanical punch), a piece of polymer material ofroughly the size of the aperture will also be formed. For an apertureformed using a conventional needle-type punch, this excess piece ofpolymer material will often become detached from the main article. Theseexcess pieces of polymer material can present difficulties for amanufacturing process flow. The excess polymer material pieces canpotentially accumulate and foul the equipment used for the manufacturingflow. Additionally or alternately, the excess polymer material piecesmay settle or lodge on other articles during manufacture. This can leadto formation of defects on the exterior of the articles, potentiallyreducing or minimizing the commercial value of the articles. Avoidingsuch fouling and defects can require increased downtime due to increasednumbers of maintenance and cleaning events.

In order to overcome one or more of the above problems, the systems andmethods provided herein allow for forming a fluid-filled chamber in anarticle composed at least in part of polymer layers while reducing orminimizing the number of tools and/or registration processes involved.The methods are enabled in part by use of a punch tool with a concavecupped surface, so that pieces of excess polymer material are notcreated during formation of the aperture. After forming the aperture,the punch can then be withdrawn to allow the same tool to dispense thefluid into the chamber. The tool can then be used as a radio-frequency(RF) welding tool to seal the chamber (such as by closing the aperture),thus retaining the fluid in the chamber. This allows the fluid-filledchamber to be formed using a single tool and/or with a reduced orminimized number of registration or alignment processes.

Formation of an Aperture

In various aspects, a single tool can be used to form an aperture in anarticle; inject or inflate a volume within the article with a fluid; andthen seal the article so that the fluid does not escape through theaperture.

A variety of polymer materials may be utilized for the layers of thearticle and/or for the portion of the article that is subject toformation of an aperture and injection with a pressurized fluid. Inselecting a polymer material for the article, engineering properties ofthe polymer material (e.g., tensile strength, stretch properties,fatigue characteristics, dynamic modulus, and loss tangent) as well asthe ability of the material to limit the diffusion of the fluidcontained within a volume in the article may be considered. When formedof thermoplastic urethane, for example, the polymer material of thearticle may have a thickness of approximately 0.89 millimeter, but thethickness may range from 0.25 to 4 0 millimeters or more, for example.In addition to thermoplastic urethane, examples of polymer materialsthat may be suitable for the article include polyurethane, polyester,polyester polyurethane, polyether polyurethane, and polyurethaneincluding a polyester polyol. Accordingly, a variety of polymermaterials may be utilized for the thermoplastic article.

Formation of an aperture can begin by contacting a layer of the articlewith a surface of a tool. The surface of the tool can be an outerannulus or other rim for a pressurization conduit. The pressurizationconduit can be a tube or other conduit that is fixed to a base for thetool on one end. The end of the conduit that contacts the surface of thearticle can be an open end, to allow fluid communication between theconduit and the layer of the article and/or an aperture created in thelayer. The contact between the surface of the tool and the surface ofthe article can be sufficient to allow a pressure greater than ambientto be maintained within the volume of the tube relative to the exteriorof the tube. In some aspects, the conduit can also serve as an electrodethat is suitable for delivery of radio frequency (RF) energy to allowfor RF welding of layers of the article after injection of fluid. Forexample, the pressurization conduit can be constructed of a metal withsufficient conductivity to allow for delivery of the RF energy. Examplesof suitable materials for the tube can include brass or aluminum.Optionally, the initial contact between the surface of the tool and thelayer of the article can be sufficient to allow for RF welding, oradditional pressure can be applied by the tool after formation of theaperture or after injection of the fluid and prior to performing RFwelding.

Contacting the surface of the pressurization conduit with the layer ofthe article can allow an elevated pressure to be maintained within thevolume in the conduit. In some aspects, the pressure within the conduitcan be about 1 psi (6.9 kPa) to about 100 psi (690 kPa) greater than thepressure outside the conduit. For example, a pressure within the conduitcan be at least about 1 psi (6.9 kPa) greater than the pressure outsidethe conduit, or at least about 3 psi (20.7 kPa) greater, or at leastabout 5 psi (34.4 kPa) greater, or at least about 10 psi (68.9 kPa)greater. Additionally or alternately, the pressure within the conduitcan be about 100 psi (690 kPa) greater than the pressure outside theconduit, or about 50 psi (345 kPa) greater. Each of the above lowerbound values is explicitly contemplated in combination with each of theabove upper bound values. This pressure differential relative to theexterior of the pressure conduit can be maintained during any or allconvenient portions of the processes of forming an aperture, injecting afluid, and sealing the aperture. In some aspects, the layer of thethermoplastic article in which the aperture is formed can be exposed tothe higher pressure within the conduit (i.e., the pressure differential)during any or all convenient portions of the processes of forming anaperture, injecting a fluid, and sealing the aperture.

The pressure differential between the interior volume of thepressurization conduit and the exterior of the pressurization conduitmay vary during the processes, but a desired differential correspondingto one of the above differential pressure values can optionally bemaintained during some or all of the processes. As an example, thepressure differential between the conduit pressure (inside the conduit)and a pressure outside of the pressurization conduit can be at leastabout 3 psi (20.7 kPa), or another of the differential values notedabove, during the injecting of one or more fluids into the chamber orother volume receiving a fluid. Additionally or alternately, such apressure differential can be maintained continuously from the forming ofthe aperture in the thermoplastic layer until the bond is formed to sealthe chamber that receives the fluid. In some aspects, the pressurewithin the pressurization conduit during one or more of the processes,or during all of the processes, can be about 15 psia (103 kPaa) to about115 psia (793 kPaa). For example, the pressure with the pressurizationconduit during one or more of the processes, or during all of theprocess, can be at least about 15 psia (103 kPaa), or at least about 16psia (110 kPaa), or at least about 18 psia (124 kPaa), or at least about20 psia (138 kPaa), and optionally up to 115 psia (793 kPaa) or less. Asnoted above, the layer of the thermoplastic article in which theaperture is formed can similarly be exposed to the higher pressurewithin the conduit (i.e., the pressure differential) during theseportions of the process.

A punch located within the tube can then be used to form the aperture inthe surface of the thermoplastic article. One option can be to manuallydrive the punch toward the thermoplastic article. In some aspects, thepunch can be driven by a repeatable and/or automatic process, such as byan actuator. For example, the punch can be driven toward the surface ofthe article using a pneumatic cylinder, such as a single-actingpneumatic cylinder. In a single-acting pneumatic cylinder, a pressurizedgas (such as air or nitrogen) can be used to exert a force on a cylinderthat is coupled to the punch. After deploying the punch to create theaperture, the pressure can be released. For a single-acting cylinder,the cylinder can then be returned to the initial position by amechanical means, such as using a spring. For example, driving thecylinder can compress a wave spring that can then expand to return thecylinder to the initial position. Alternatively, a spring mechanism thatbecomes extended when the cylinder is moved can also be used to returnthe punch to the initial position. Of course, other types of actuators,such as double-acting pneumatic cylinders or other mechanical orelectromagnetic actuators, can also be used to control the punch.

After forming the aperture, the punch is withdrawn from the aperturesuch as by use of a spring mechanism as described above. A fluid canthen be injected into a volume in the article by passing the fluid fromthe conduit and into the volume via the aperture. The fluid can bedelivered into the conduit from a fluid source, such as a pressurizednitrogen or pressurized air source. The fluid can pass around the punchin the conduit due to a clearance distance between the punch and theinner perimeter of the conduit. The clearance distance at all locationswithin the conduit can be about 0.0025 inches (0.064 mm) to about 0.012inches (0.30 mm). For example, the clearance between the punch and theinner perimeter of the conduit can be at least about 0.0025 inches(0.064 mm) at all locations within the conduit, or at least about 0.004inches (0.10 mm) or at least about 0.005 inches (0.13 mm). Additionallyor alternately, the clearance between the punch and the inner perimeterof the conduit can be about 0.012 inches (0.30 mm) or less, such asabout 0.010 inches (0.25 mm) or less. Each of the above lower boundvalues is explicitly contemplated in combination with each of the aboveupper bound values. The clearances for the punch within thepressurization conduit can allow the punch to remain sufficientlyaligned while maintaining an acceptable pressure drop between the fluidsource and the open (exit) end of the pressurization conduit.

It is noted that the inner perimeter or circumference of thepressurization conduit may vary along the height of the conduit. Forexample, it may be desirable to have a punch head with a larger crosssection than the remaining portion of the punch. In order to reduce thevolume of gas required to maintain pressure within the pressurizationconduit, the conduit can be shaped to have the desired clearance withthe punch in the first position. Thus, the inner perimeter orcircumference of the conduit can be narrower for the main body of thepunch, with the conduit broadening to a larger inner perimeter orcircumference to accommodate the punch head. When the punch is deployed(such as to the second position) to form an aperture, the punch headwill move out of the conduit, resulting in addition clearance between aportion of the punch and a portion of the inner perimeter of theconduit. However, during most of the operation of the tool, the punchwill be substantially within the conduit. The outer perimeter of theconduit can have similar variations in size along the length of theconduit. Of course, the inner perimeter and/or outer perimeter of theconduit can also be varied for any other convenient reason along thelength of the conduit.

The pressurized fluid delivered into the volume within the article canbe any convenient fluid. For example, the pressurized fluid can be apressurized gas such as nitrogen or air. More generally, the fluiddelivered into the volume in the thermoplastic article may range inpressure from about zero to about three-hundred-fifty kilopascals (i.e.,approximately fifty-one pounds per square inch) or more. In addition toair and nitrogen, the fluid delivered into the volume may includeoctafluorapropane and/or any of the gasses disclosed in U.S. Pat. No.4,340,626 to Rudy, such as hexafluoroethane and sulfur hexafluoride. Insome configurations, the volume containing the pressurized fluid may beincorporated into a fluid system, as disclosed in U.S. Pat. No.7,210,249 to Passke, et al., as either a pump chamber or a pressurechamber. In some configurations, the volume containing the pressurizedfluid may incorporate a valve that permits the individual to adjust thepressure of the fluid within the volume. It is noted that the fluid usedto initially pressurize the conduit prior to forming the aperture doesnot have to be identical to the fluid that is passed via the apertureinto the volume within the article.

In various aspects, separate fluid sources can be used to provide fluidfor a pneumatic cylinder and the fluid for the pressurization conduit.For example, a suitable pressure for a pneumatic cylinder can range fromabout 50 psig (345 kPag) to about 120 psig (827 kPag). By contrast, thedesired pressure for the pressurization conduit can be about 100 psig(690 kPag) or less, or 50 psig (345 kPag) or less, down to a pressurejust above ambient such as 1 psig (7 kPag), which might correspond to anabsolute pressure of 15 psia (103 kPaa) or 16 psia (110 kPaa). As aresult, in some aspects the fluid delivery conduit for thepressurization conduit may not be in fluid communication with the fluiddelivery conduit for the pneumatic cylinder.

Based on the elevated pressure within the volume in the conduit, theinterior of the article is not exposed to the outside atmosphere.Instead, the pressurized fluid within the conduit can be injected intoone or more volumes that are in fluid communication with the tool viathe aperture. In some aspects, the punch can form an aperture in fewerthan all of the layer of the article, such as forming an aperture onlyin an upper and/or first layer of the article while leaving one or morelower layers intact.

After forming the aperture, the tool can be used to seal the volume(s)in the thermoplastic article so that the pressurized fluid is retainedwithin the volume(s). This can be achieved by sealing the aperture or bysealing any other convenient location in the thermoplastic article thatretains at least a majority of the pressurized fluid. One option forsealing the volume(s) is to perform radio frequency (RF) welding on thearticle. RF welding of plastic layers to form a substantially air-tightseals is a well-known process. The contact of the conduit with thesurface of the article can provide the necessary force (pressure) formaintaining contact of two (or more) plastic layers during welding. Insome aspects, the conduit can serve as an electrode, so that the RFenergy for welding can be delivered by the conduit to the layers of thearticle for heating of the layers. The RF energy can then heat theplastic layers to form a bond that substantially prevents the fluid thatwas injected into the volume from escaping from the volume.

Tool for Formation of an Aperture

In various aspects, a single tool can be used to form an aperture in anarticle; load or inflate a volume within the article with a fluid; andthen seal the article so that the fluid does not escape through theaperture.

To facilitate formation of an aperture, the tool can include an outertube or conduit for contacting a surface and an internal punch forforming the aperture. In some aspects, the tube or conduit can have anannular shape. In other aspects, the conduit can have an elliptical orsubstantially elliptical shape. A substantially elliptical shape refersto a shape that can vary from an elliptical shape by up to 10% of aminor or major axis value at any location on the ellipse. Of course, acircular shaped conduit (an annulus) is merely a special case of anellipse. In various aspects, the axis of movement for the internal punchcan be concentric or substantially concentric with a central axis of theconduit. In some aspects, the tip of the punch or punch head (the endthat contacts the polymer layer) can include an edge, with the edgedefining the perimeter of a cupped or concave portion of the punch headsurface. Optionally, the edge defining the cupped portion of the surfacecan have a sufficiently sharp edge to facilitate forming an aperture.

The cupped portion of the punch surface can define a conical shape, ann-sided pyramidal shape (where n is greater than or equal to three,optionally twenty or less, or twelve or less), a frustum volume of sucha conical or n-sided pyramidal shape, or a volume section of an ovoid orspheroid shape. In some aspects, the volume defined by the cuppedportion (the punch volume) is a shallow volume relative to the diameterof the base of the cupped portion (which corresponds to the shapedefined by the edge).

As an example, the average depth of the cupped portion (punch depth) canbe less than the average distance defined by the two opposing points ofthe edge that defines the base of the cupped portion (an averagediameter), such as having an average depth of the cupped portion that isless than 0.75 times the average diameter of the base, or less thanabout 0.5 times the average diameter, or less than about 0.4 times thediameter. Additionally or alternately, the depth of the cupped portion(punch depth) can be at least about 0.2 times the average diameter ofthe base, such as at least about 0.25 times the average diameter, or atleast about 0.4 times the average diameter, or at least about 0.5 timesthe average diameter. Examples of average depth ranges include, but arenot limited to, 0.2 times to 0.75 times the average diameter of thebase, or 0.2 times to 0.5 times, or 0.2 times to 0.4 times, or 0.25times to 0.75 times, or 0.25 times to 0.5 times, or 0.25 times to 0.4times, or 0.4 times to 0.75 times, or 0.4 times to 0.5 times, or 0.5times to 0.75 times.

In some additional and/or alternative aspects, the depth of the cuppedportion of the punch can be selected based on the thickness of a surfaceor layer of the article where the aperture is formed. In order to beeffective for opening an aperture, the depth of the cupped portion canbe at least about the thickness of the layer, such as about 1.0 timesthe thickness of the layer to about 3.0 times the thickness of thelayer. For example, the depth of the cupped portion can be at leastabout 1.0 times the thickness of the layer or at least about 1.5 timesthe thickness of the layer. Additionally or alternately, the depth ofthe cupped portion can be about 3.0 times the thickness of the layer orless, such as about 2.5 times the thickness of the layer or less, orabout 2.0 times the thickness of the wall or less, or about 1.6 timesthe thickness of the wall or less. Each of the above lower bound valuesis explicitly contemplated in combination with each of the above upperbound values. Such values for the depth of the cupped portion can besuitable for causing the remnant of material formed after opening theaperture to remain with the thermoplastic article.

In some further additional and/or alternative aspects, for cuppedportions corresponding to a conical, pyramidal, or frustum volume, theshallow nature of the cupped portion relative to the diameter of thepunch surface can be defined based on the angle of the walls of thecupped surface relative to the edge that defines the cupped surface. Ifthe wall of the cupped portion were aligned with the long axis of thepunch, the angle between the wall and the flat rim would be 90 degrees.In the limit of an angle of 180 degrees, the cupped portion would beeliminated and instead the surface of the punch would be a flat plane.In various aspects, the angle defined by the walls of the cupped portioncan be greater than 110 degrees, or at least 120 degrees, or at least135 degrees, and/or optionally less than 160 degrees, or less than 150degrees.

FIGS. 1a and 1b show an example of a side cutaway view of a punch 100having an edge 105 that defines a cupped portion 110 of the surface thathas a volume 130. As shown in FIG. 1 b, the angle 115 defined by thecupped portion 110 can be an angle between 90 and 180 degrees. FIG. 1bshows an example of a punch where the included angle for the cuppedportion of the surface of the punch head is between about 115 degreesand about 120 degrees. As shown in FIG. 1 b, the depth 135 of the cuppedvolume 130 is less than the diameter of the edge 105 that defines thecupped volume 130.

FIG. 2 shows an example of a unified tool for forming an aperture in alayer of an article, injecting a fluid into a volume within the article,and sealing the article to substantially retain the fluid within thevolume. In FIG. 2, punch head 201 is part of punch 205. At least aportion of punch 205 (including punch head 201) resides within a tube orconduit 212. Optionally, the axis of the punch 205 can be concentricwith the axis of the conduit 212.

In a first position, the punch 205 can reside within a conduit or tube,such as conduit 212 as shown in FIG. 2. As shown in FIG. 2, both theinner perimeter and outer perimeter of the conduit 212 can vary alongthe height of the conduit. The bottom or end surface 215 of the conduitcan extend past the punch in the first position. During operation of thetool the punch can be deployed past the bottom surface of the tube inorder to form an aperture. The maximum length of deployment for thepunch can define a second position. Optionally, the length of deploymentfor the punch can be adjustable, such as by mechanically coupling thepunch to an actuator via a threaded screw coupling. The first positionand/or the second position for the punch can then be adjusted bymodifying the location of the mechanical coupling relative to the screwcoupling.

Conduit 212 is mounted on or otherwise coupled to a primary structure orbase 220. Base 220 also includes a cylinder 230 that is coupled to punch205. In the example shown in FIG. 2, the actuator for the punch 205corresponds to a single acting pneumatic cylinder. In FIG. 2, punch 205is coupled to cylinder 230 via a screw mechanism. The screw mechanismcan be used to adjust the height of the punch 205 relative to the tube212. A height adjustment for punch 205 can be based on a desired heightat the rest position, a desired length of deployment for the punch head201 beyond end surface 215 of conduit 212, or the height can be adjustedfor any another convenient reason. Pressure to move the cylinder 230along the axis is motion can be provided from a fluid source (not shown)via fluid conduit 242. The cylinder 230 of the actuator is positioned towork in conjunction with spring mechanism 235, which can provide theforce to return the cylinder to a first (starting) position after thepressure above the cylinder head is released. The first position forcylinder 230 can correspond to a natural length or rest length for thespring mechanism 235, or the first position can be defined by amechanical stop so that the cylinder 230 is biased against themechanical stop by the spring 235. When the cylinder 230 is moved tocompress the spring mechanism 235, the punch 201 is moved relative tothe tube 212. This allows the punch 201 to be deployed beyond the endsurface 215 of tube 212.

During operation to form an aperture in a polymer layer of an article,end surface 215 of conduit 212 can be contacted with the surface of thearticle. The end surface 215 can form a sufficient seal with the surfaceof the article to maintain a pressure greater than the surroundingatmosphere within the interior of conduit 212. The interior volume canbe pressurized based on a gas flow passed around the exterior of punch205 in tube 212. In FIG. 2, the gas flow is introduced via a secondfluid conduit 247, which is in fluid communication with a second fluidsource (not shown).

Punch 205 can then be deployed to form an aperture in the surface. Dueto the cupped nature of the tip 202 of punch head 201, the remnantmaterial of the plastic layer that is created when the aperture isformed can remain with the plastic layer. After forming the aperture,the punch 205 is withdrawn (such as due to the restoring force providedby spring 235). The pressurized fluid within conduit 212 can be used tofill or at least partially fill a chamber in the plastic article. Theamount of pressurized fluid injected into the chamber can depend on thepressure of the fluid within conduit 212.

After injecting fluid into the chamber, the end surface 215 of conduit212 can be pressed onto the surface of the polymer layer with additionalforce to allow for RF welding. This can allow a seal to form around theaperture so that the injected fluid is substantially retained within thechamber of the plastic article.

FIGS. 3a and 3b show an example of deploying a punch to form an aperturein a layer of an article. In FIGS. 3a and 3b , the end surface 315 ofthe tool is shown separated from the top of layer 350 for ease ofviewing. It is understood that during formation of an aperture, endsurface 315 will typically be in contact with layer 350. When endsurface 315 is initially brought into contact with layer 350, the punchhead 301 can be in a first position corresponding to FIG. 3a . Thisfirst position can be used to form a seal between end surface 315 andlayer 350. The punch head 301 can then be deployed to a position such asthe position shown in FIG. 3b . This position can cause an aperture tobe formed in layer 350. In some aspects, the depth of the cupped surface341 of punch head 301 is sufficient to allow the aperture to form inlayer 350 while allowing the material originally occupying the aperturelocation to remain with layer 350.

Example of Inflation: Chamber in Sole of Article of Footwear

One application for unified punch and inflation tool is for inflation ofa chamber in the sole of an article of footwear. After forming the solefor a shoe (or other footwear), such as by a molding process, a chamberwithin the sole can be inflated to improve one or more characteristicsof the sole and/or footwear. FIGS. 4-10D show an example configurationfor an article of footwear with a chamber that can be inflated. Ofcourse, other types of articles of footwear with other locations forinflation of a chamber may also be inflated using a tool as describedherein.

An article of footwear 10 is depicted in FIGS. 4 and 5 as including anupper 20 and a sole structure 30. For reference purposes, footwear 10may be divided into three general regions: a forefoot region 11, amidfoot region 12, and a heel region 13, as shown in FIGS. 4 and 5.Footwear 10 also includes a lateral side 14 and a medial side 15.Forefoot region 11 generally includes portions of footwear 10corresponding with the toes and the joints connecting the metatarsalswith the phalanges. Midfoot region 12 generally includes portions offootwear 10 corresponding with the arch area of the foot, and heelregion 13 corresponds with rear portions of the foot, including thecalcaneus bone. Lateral side 14 and medial side 15 extend through eachof regions 11-13 and correspond with opposite sides of footwear 10.Regions 11-13 and sides 14-15 are not intended to demarcate preciseareas of footwear 10. Rather, regions 11-13 and sides 14-15 are intendedto represent general areas of footwear 10 to aid in the followingdiscussion. In addition to footwear 10, regions 11-13 and sides 14-15may also be applied to upper 20, sole structure 30, and individualelements thereof.

Upper 20 is depicted as having a substantially conventionalconfiguration incorporating a plurality material elements (e.g.,textile, foam, leather, and synthetic leather) that are stitched oradhesively bonded together to form an interior void for securely andcomfortably receiving a foot. The material elements may be selected andlocated with respect to upper 20 in order to selectively impartproperties of durability, air-permeability, wear-resistance,flexibility, and comfort, for example. An ankle opening 21 in heelregion 13 provides access to the interior void. In addition, upper 20may include a lace 22 that is utilized in a conventional manner tomodify the dimensions of the interior void, thereby securing the footwithin the interior void and facilitating entry and removal of the footfrom the interior void. Lace 22 may extend through apertures in upper20, and a tongue portion of upper 20 may extend between the interiorvoid and lace 22. Given that various aspects of the present applicationprimarily relate to sole structure 30, upper 20 may exhibit the generalconfiguration discussed above or the general configuration ofpractically any other conventional or non-conventional upper.Accordingly, the overall structure of upper 20 may vary significantly.

Sole structure 30 is secured to upper 20 and has a configuration thatextends between upper 20 and the ground. In effect, therefore, solestructure 30 is located to extend between the foot and the ground. Inaddition to attenuating ground reaction forces (i.e., providingcushioning for the foot), sole structure 30 may provide traction, impartstability, and limit various foot motions, such as pronation. Theprimary elements of sole structure 30 are a plate 40, a chamber 50, andan outsole 60, as depicted in FIGS. 6 and 7. Plate 40 forms an upperportion of sole structure 30 and is positioned adjacent to upper 20.Chamber 50 forms a middle portion of sole structure 30 and is positionedbetween plate 40 and outsole 60. In addition, outsole 60 forms a lowerportion of sole structure 30 and is positioned to engage the ground.Each of plate 40, chamber 50, and outsole 60 extend around a perimeterof sole structure 30 and have a shape that generally corresponds with anoutline of the foot. More particularly, plate 40, chamber 50, andoutsole 60 extend from forefoot region 11 to heel region 13 and alsofrom lateral side 14 to medial side 15. Accordingly, each of plate 40,chamber 50, and outsole 60 are exposed to an exterior of footwear 10 andcooperatively form a side surface of sole structure 30.

Chamber 50, which is depicted individually in FIGS. 8-10D, is formedfrom a polymer material that provides a sealed barrier for enclosing afluid. The polymer material defines an upper surface 51, an oppositelower surface 52, and a sidewall surface 53 that extends around aperiphery of chamber 50 and between surfaces 51 and 52. As discussedabove, chamber 50 has a shape that generally corresponds with an outlineof the foot. As with plate 40 and outsole 60, chamber 50 is exposed toan exterior of footwear 10 and forms a portion of the side surface ofsole structure 30. More particularly, sidewall surface 53 is exposed tothe exterior of footwear 10 around substantially all of the side surfaceof sole structure 30.

Chamber 50 includes various bonded areas 54 where upper surface 51 isbonded or otherwise joined to lower surface 52. In general, bonded areas54 are spaced inward from sidewall surface 53 and form variousdepressions or indentations in each of surfaces 51 and 52. Some of thedepressions in upper surface 51 are shaped to receive variousprojections that extend downward from plate 40. That is, the projectionsof plate 40 extend into the depressions formed by portions of bondedareas 54. Similarly, some of the depressions in lower surface 52 areshaped to receive various projections that extend upward from outsole60. That is, the projections of outsole 60 also extend into thedepressions formed by portions of bonded areas 54.

Bonded areas 54 also form various subchambers within chamber 50. Forexample, a peripheral subchamber 55 extends around the periphery ofchamber 50 and a plurality of interior subchambers 56 arecentrally-located in chamber 50. Various conduits may connectsubchambers 55 and 56 such that the fluid within chamber 50 may passbetween subchambers 55 and 56. In some configurations, the conduits maybe absent or sealed to prevent fluid transfer between subchambers 55 and56. When the conduits are absent or sealed, the fluid within subchambers55 and 56 may be pressurized to different degrees.

In addition to bonded areas 54, an inflation area 57 has a configurationwherein upper surface 51 is bonded or otherwise joined to lower surface52. Inflation area 57 is spaced inward from sidewall surface 53. Moreparticularly, inflation area 57 is located in midfoot region 12,centered between sides 14 and 15, and extends through a center of one ofinterior subchambers 56. As described in greater detail below, chamber50 is inflated through inflation area 57 and has the advantages of (a)imparting a clean, relatively unbroken appearance to sidewall surface53, (b) reducing the quantity of residual polymer material producedduring the manufacturing process, and (c) decreasing the size of a moldthat is utilized during the manufacturing process.

A variety of polymer materials may be utilized for chamber 50. Inselecting a polymer material for chamber 50, engineering properties ofthe polymer material (e.g., tensile strength, stretch properties,fatigue characteristics, dynamic modulus, and loss tangent) as well asthe ability of the material to limit the diffusion of the fluidcontained by chamber 50 may be considered. When formed of thermoplasticurethane, for example, the polymer material of chamber 50 may have athickness of approximately 0.89 millimeter, but the thickness may rangefrom 0.25 to 4.0 millimeters or more, for example. In addition tothermoplastic urethane, examples of polymer materials that may besuitable for chamber 50 include polyurethane, polyester, polyesterpolyurethane, polyether polyurethane, and polyurethane including apolyester polyol. Accordingly, a variety of polymer materials may beutilized for chamber 50.

In manufacturing chamber 50, both a molding process and an inflationprocess are utilized. The molding process involves shaping a polymermaterial to define the general configuration of chamber 50. Moreparticularly, the molding process includes shaping the polymer materialto form surfaces 51-53 and also form bonded areas 54 to definesubchambers 55 and 56. Although not performed during some moldingprocesses, a portion of inflation area 57 may also be formed orotherwise defined. Once the molding process is complete, an inflationprocess as described above can be utilized to pressurize and sealchamber 50.

In this description, reference is made to combinations involving “anyof” a number of embodiments, aspects, and/or claims. The term “any of”is understood to include any possible combination of at least one of theembodiments, aspects, and/or claims in the recited range, including “anyone of”.

The description above and the accompanying figures provide a variety ofconfigurations. The purpose served by the disclosure is to provide anexample of various features and concepts. One skilled in the relevantart will recognize that numerous variations and modifications may bemade to the configurations described above without departing from thescope of the present disclosure, as defined by the appended claims.

1-20. (canceled)
 21. A tool for introducing fluid into a sealed volumecomprising: an electrode having an outer circumference and an innercircumference, the inner circumference defining a volume within theelectrode, the electrode being mechanically coupled to a base at a firstend of the electrode, the electrode being open at a second end; anactuator mechanically coupled to the base; a punch having a punch head,the punch being coupled to the actuator, the punch head residing withinthe volume in the electrode in a first punch position and being outsideof the volume of the electrode in a second punch position, the punchhead comprising a punch edge defining a perimeter, a surface of thepunch within the perimeter of the punch edge being concave and defininga punch volume, an average depth of the punch volume being less than anaverage diameter of the punch edge; and a first fluid delivery conduit,the first fluid delivery conduit being in fluid communication with thevolume in the electrode and in fluid communication with the opening atthe second end of the electrode.
 22. The tool of claim 21, wherein thepunch volume is a conical volume or a conical frustum volume.
 23. Thetool of claim 21, wherein the punch volume is a spheroid volume or anovoid volume.
 24. The tool of claim 21, wherein the punch volume is ann-sided pyramidal volume where n is greater than or equal to three or afrustum volume based on an n-sided pyramidal volume where n is greaterthan or equal to three.
 25. The tool of claim 21, wherein an includedangle at opposing points of the circumference of the punch is about 120°to about 160°.
 26. The tool of claim 21, wherein the average depth ofthe punch volume is less than 0.5 times an average diameter of theperimeter of the edge.
 27. The tool of claim 21, wherein the punch ismechanically coupled to the actuator by an adjustable mechanicalcoupling, the height of the punch head in the first position beingadjustable based on the adjustable mechanical coupling.
 28. The tool ofclaim 27, wherein at least a portion of the punch is threaded, the punchbeing coupled to the actuator by a threaded screw coupling.
 29. The toolof claim 21, wherein the actuator comprises a pneumatic cylinder. 30.The tool of claim 29, wherein a piston volume of the pneumatic cylinderis in fluid communication with a second fluid delivery conduit.
 31. Thetool of claim 29, wherein the pneumatic cylinder is a single actingpneumatic cylinder.
 32. The tool of claim 31, wherein a restoring forcefor the single acting pneumatic cylinder is provided by a spring. 33.The tool of claim 21, wherein the inner circumference of the electrodeis substantially circular.
 34. The tool of claim 21, wherein the innercircumference of the electrode varies along a height of the electrode.35. The tool of claim 21, wherein an axis of the punch is substantiallyconcentric with an axis of the electrode.
 36. The tool of claim 35,wherein the actuator is a pneumatic cylinder, the axis of the punchsubstantially corresponding to an axis of motion of the pneumaticcylinder.
 37. The tool of claim 21, wherein the first punch position andthe second punch position are separated by a distance along an axis ofmotion of the actuator.
 38. The tool of claim 21, wherein the actuatoris substantially contained within the base.
 39. The tool of claim 21,wherein a clearance between the punch and the inner circumference isfrom about 0.0025 inches (0.064 mm) to about 0.01 inches (0.25 mm). 40.The tool of claim 21, wherein a clearance between the punch head and theinner circumference is from about 0.0025 inches (0.064 mm) to about 0.01inches (0.25 mm).